Aftermarket exhaust installation- where to cut the header??

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21 Mar 2020 14:51 #821330 by KZOO440
Alright. I got a pair of universal aftermarket slip ons and I am trying to figure out where I need to cut the old stock exhaust to get the new mufflers to fit. My first cut was after the cross pipe but it looks like its the same diameter as the new muffler (will not slip over). The pipes came with reducer collars but I dont think I can use that to slip inside the header and then slip the new muffler over it. I could not find any guide on how to properly use the reducers so im just guessing here.

Am I going to have to cut the header and lose the cross pipe? I'm worried about the new pipes mounting too far forward and also loosing low end power.

The pipes are already cut so im at least commiting to straight pipes. Here are some pictures:

1980 KZ440 LTD
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21 Mar 2020 16:28 #821343 by riturbo
If you take those adapter pieces out the muffler wont fit over the pipe . Looks like it would .

Gpz 750 turbo The one I ride
Gpz 750 turbo Not finished
Gpz 750 turbo Not started
Gpz 550 1981
Gpz 550 1983
Bunch of other junk

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21 Mar 2020 16:42 #821346 by KZOO440
I think that is just the camera angle. When you put them together without the adapters they are the smae size.

1980 KZ440 LTD

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21 Mar 2020 19:51 #821366 by Nerdy
If you cut the pipe ahead of the crossover, the outer diameter (OD) of the pipe will be 1.5".

What is the inner diameter of the mufflers?

1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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22 Mar 2020 06:36 #821391 by KZOO440
The inlet OD is 1 3/4". here is a link to the mufflers: www.dimecitycycles.com/chrome-17-inch-sh...gaphone-muffler.html

1980 KZ440 LTD

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22 Mar 2020 06:47 - 22 Mar 2020 07:00 #821392 by martin_csr
Maybe install only one of the adapters & use screws to secure it to the header pipe assembly, then clamp on the muffler. I'm assuming the adapter is long enough. Or get a more suitable adapter that can be affixed to the header pipe. ???
Last edit: 22 Mar 2020 07:00 by martin_csr.

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22 Mar 2020 10:33 - 22 Mar 2020 10:35 #821405 by KZOO440
I think ill cut it at the header to get the 1.5" pipe size since im pretty sure that will fit. I'll mount the mufflers like that and if they dont fit/interfere then I'll see if I can find/fab an exhaust adapter to get the mufflers where they need to go. This will delete the cross pipe but I'm hoping it will get me riding at least.

Ill post an update tonight (hopefully) of how it went.

1980 KZ440 LTD
Last edit: 22 Mar 2020 10:35 by KZOO440.

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22 Mar 2020 14:35 #821433 by martin_csr
If possible, I would avoid eliminating the crossover pipe. I don't know much about the 440s, though.

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22 Mar 2020 18:13 #821458 by KZOO440
It turns out that the mufflers would have fit over the pipe. I did not find that out until after I cut it and hit it with a mallet (pictures 6 and 7). whoops.

When I made the cut I found a second layer of pipe that I was not expecting. Once it was off I tried to use the adapters to go from 1.5"OD on the header to 1.75" ID of the muffler. Pictures 3, 4, and 5 show how I set up the adpaters. No matter how I tried it I could not get the adapters to work. If i put them on the header first than they stretched out too far for the muffler to fit and if I put them in the muffler first then they were too tight to fit over the header.
I tried to telescope them out and compress it don but that did not work either.

If anyone knows what I am doing wrong with the adapters I would love to know.

I contacted a local fab shop about making a H-pipe that will slide over the headers and allow the mufflers to slide over them. Im hoping it will be relatviely cheap, allow me to keep the cross pipe, and give me more flexibilty with the location of the mufflers. The last picture shows roughly what I want to have made, without the stock muffler.

1980 KZ440 LTD

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13 Apr 2020 18:47 #823278 by KZOO440
Here are some pictures of the new mufflers. Went to Heman Fabrication in Indianapolis and he did an awesome job fitting the mufflers to keep that stock look. Ended up without the crossover pipe but after 60 miles I dont notice any power loss. if it is there then the pipes are not the power bottleneck.

A note about the Dime City Cycle mufflers. after about 6 miles there was insualtion coming out of the back of the muffler (see in the pictures). I ordered a 500g bag of Moose Racing Insulation to repack the mufflers and hopefully quiet them down a bit.

1980 KZ440 LTD
The following user(s) said Thank You: LandLeftBehind

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